Terrain-following solar tracker system

This application claims benefit of and hereby incorporates by reference U.S. provisional application Ser. No. 63/656,485, entitled “TERRAIN-FOLLOWING SLEW DRIVE SYSTEM,” filed on Jun. 5, 2024, by inventors Gregory P. Huzyak et al.

This invention relates generally to systems and methods for a tracker system suited for uneven terrains.

A tracker system is configured to orient solar panels with movement of the sun. Often, natural terrain on which a tracker system is installed may be uneven, which causes difficulties in connecting several solar canopies in a chain. Efforts to address these limitations using extensive grading or by using posts with precisely controlled lengths has proven unruly and burdensome. Therefore, a tracker system that is adaptable to uneven terrain would be helpful.

A terrain-following tracker system includes solar canopies connected to each other by a terrain-following drive system and/or by a terrain-following clamping system.

The terrain-following drive system causes tilting of the first solar canopy about a first axis and tilting of the second solar canopy about a second axis. The drive system includes a drive, an articulating joint, a first output shaft, and a second output shaft. The drive includes a slewing drive that may include a ring gear rotatable by a worm screw. The worm screw may be rotated by a drive motor. Along a first side relative to the drive, the drive is coupled to the articulating joint, which is coupled to the first output shaft. The first output shaft is coupled to the first solar canopy. Along a second, opposite side relative to the drive, the drive is further coupled to a second output shaft. On the first side, rotation of the ring gear causes rotation of the articulating joint, which in turn causes rotation of the first output shaft and tilting of the first solar canopy about the first axis. Along the second side, rotation of the ring gear causes rotation of the second output shaft, which in turn causes tilting of the second solar canopy about the second axis.

In some embodiments, the articulating joint may enable angular adjustment between the first axis and the second axis by several degrees, e.g., up to 25 degrees (whether vertically or laterally or both). In some embodiments, an articulating joint may be disposed on each side of the drive to double the amount of adjustment available between the first axis and the second axis.

In some embodiments, the first solar canopy includes a first torque tube, first solar panels and a first support structure attaching the first solar panels to the first torque tube. In some embodiments, the second solar canopy includes a second torque tube, second solar panels and a second support structure attaching the second solar panels to the second torque tube.

The terrain-following tracker system may be secured to a terrain surface via a drive post (e.g., posts with an adjacent, proximate, or attached drive system) and clamping or idle posts (e.g., posts without an adjacent, proximate, or attached drive system). Because of the articulating joint, each drive post or clamping post may not have strict height requirements. Thus, instead of having to grade the terrain to be substantially planar, the articulating joint assists the tracker system to be terrain following.

To impart additional terrain following functionality, the drive system may be attached to the drive post in a manner that permits tilting of the drive system relative to the drive post. In some embodiments, the terrain-following tracker system may include a pivotable post bracket system.

As indicated above, the terrain-following tracker system may also include terrain-following clamping systems. Terrain-following clamping systems may securely attach adjacent solar canopies to each other or attach a solar canopy to a clamping post. For example, terrain-following clamping systems may securely attach the first solar canopy to a third solar canopy along the first side of the drive. Terrain-following clamping systems may include articulating clamping systems or non-articulating clamping systems.

An articulating clamping system has an adjacent or proximate articulating joint, while a non-articulating clamping system is lacking an adjacent or proximate articulating joint. For example, an articulating clamping assembly positioned between the first and third solar canopies may cause the third solar canopy to tilt at a third angle which may be different from the first angle or the second angle. As another example, a non-articulating clamping assembly positioned between the first and third solar canopies may cause the third solar canopy to tilt at approximately the first angle, to match the tilt of the adjacent solar panel.

In some embodiments, a drive system comprises a ring gear configured to rotate about a first axis; a first articulating joint including a driving yoke, a driven yoke and a spider coupling the driving yoke to the driven yoke, the driving yoke coupled to the drive gear and configured to rotate about the first axis, the driven yoke configured to rotate about a second axis; a first output shaft coupled to the driven yoke and configured to be coupled to a first solar canopy, the first output shaft configured to induce tilt in the first solar canopy; and a pivotable post bracket system coupled to the ring gear, the pivotable post bracket system configured to be coupled to a post and configured to pivot relative to the post.

The pivotable post bracket system may comprise a pivoting post bracket and a drive bracket. The pivoting post bracket may comprise fastener slots, each of the fastener slots configured to hold a fastener to affix the pivoting post bracket to a post and enable pivoting of the pivoting post bracket relative to the post. The fastener slots may comprise arcuate slots. The fastener slots may be symmetrically distributed. The first output shaft may include an articulating joint bracket, an offset link, and a torque tube interface. The first articulating joint may be coupled to a first side of the ring gear, and the drive system may further comprise a second output shaft coupled to a second side of the ring gear and configured to be coupled to a second solar canopy. The drive system may comprise a second articulating joint coupled between the second side of the ring gear and the second output shaft. The ring gear may include first mating fasteners, and the drive system may further comprise second mating fasteners coupling the first articulating joint to the first mating fasteners. The drive system may comprise first mating fasteners and second mating fasteners coupling the first articulating joint to the first output shaft.

In some embodiments, a terrain-following tracker system comprises a first post; a second post; a first solar canopy between the first post and the second post; a drive system coupled between the first post and the first solar canopy, the drive system comprising: a ring gear configured to rotate about a first axis; a first articulating joint including a driving yoke, a driven yoke and a spider coupling the driving yoke to the driven yoke, the driving yoke coupled to the drive gear and configured to rotate about the first axis, the driven yoke configured to rotate about a second axis; a first output shaft coupled to the driven yoke and to the first solar canopy, the first output shaft configured to induce tilt in the first solar canopy; and a pivotable post bracket system coupled to the ring gear, the pivotable post bracket system coupled to the first post and configured to pivot relative to the first post; and a clamping system coupled between the second post and the first solar canopy and configured to tilt in response to the tilt of the first solar canopy.

The clamping system may include a non-articulating clamping system. The clamping system may include an articulating clamping system. The articulating clamping system may include a second articulating joint. The second articulating joint may be positioned between the second post and the first solar canopy. The pivoting post bracket may comprise fastener slots, each of the fastener slots configured to hold a fastener to affix the pivoting post bracket to the first post and enable pivoting of the pivoting post bracket relative to the first post. The fastener slots may comprise arcuate slots. The first articulating joint may be coupled to a first side of the ring gear, and the terrain-following tracker system may further comprise a second output shaft coupled to a second side of the ring gear and configured to be coupled to a second solar canopy. The ring gear may include first mating fasteners, and the terrain-following tracker system may further comprise second mating fasteners coupling the first articulating joint to the first mating fasteners. The terrain-following tracker system may comprise first mating fasteners and second mating fasteners coupling the first articulating joint to the first output shaft.

A terrain-following tracker system includes solar canopies connected to each other by a terrain-following drive system and/or by a terrain-following clamping system.

The terrain-following drive system causes tilting of the first solar canopy about a first axis and tilting of the second solar canopy about a second axis. The drive system includes a drive, an articulating joint, a first output shaft, and a second output shaft. The drive includes a slewing drive that may include a ring gear rotatable by a worm screw. The worm screw may be rotated by a drive motor. Along a first side relative to the drive, the drive is coupled to the articulating joint, which is coupled to the first output shaft. The first output shaft is coupled to the first solar canopy. Along a second, opposite side relative to the drive, the drive is further coupled to a second output shaft. On the first side, rotation of the ring gear causes rotation of the articulating joint, which in turn causes rotation of the first output shaft and tilting of the first solar canopy about the first axis. Along the second side, rotation of the ring gear causes rotation of the second output shaft, which in turn causes tilting of the second solar canopy about the second axis.

In some embodiments, the articulating joint may enable angular adjustment between the first axis and the second axis by several degrees, e.g., up to 25 degrees (whether vertically or laterally or both). In some embodiments, an articulating joint may be disposed on each side of the drive to double the amount of adjustment available between the first axis and the second axis.

In some embodiments, the first solar canopy includes a first torque tube, first solar panels and a first support structure attaching the first solar panels to the first torque tube. In some embodiments, the second solar canopy includes a second torque tube, second solar panels and a second support structure attaching the second solar panels to the second torque tube.

The terrain-following tracker system may be secured to a terrain surface via a drive post (e.g., posts with an adjacent, proximate, or attached drive system) and clamping or idle posts (e.g., posts without an adjacent, proximate, or attached drive system). Because of the articulating joint, each drive post or clamping post may not have strict height requirements. Thus, instead of having to grade the terrain to be substantially planar, the articulating joint assists the tracker system to be terrain following.

To impart additional terrain following functionality, the drive system may be attached to the drive post in a manner that permits tilting of the drive system relative to the drive post. In some embodiments, the terrain-following tracker system may include a pivotable post bracket system.

As indicated above, the terrain-following tracker system may also include terrain-following clamping systems. Terrain-following clamping systems may securely attach adjacent solar canopies to each other or attach a solar canopy to a clamping post. For example, terrain-following clamping systems may securely attach the first solar canopy to a third solar canopy along the first side of the drive. Terrain-following clamping systems may include articulating clamping systems or non-articulating clamping systems.

An articulating clamping system has an adjacent or proximate articulating joint, while a non-articulating clamping system is lacking an adjacent or proximate articulating joint. For example, an articulating clamping assembly positioned between the first and third solar canopies may cause the third solar canopy to tilt at a third angle which may be different from the first angle or the second angle. As another example, a non-articulating clamping assembly positioned between the first and third solar canopies may cause the third solar canopy to tilt at approximately the first angle, to match the tilt of the adjacent solar panel.

illustrates an example terrain-following tracker systemaccording to some embodiments of the present invention. The terrain-following tracker systemincludes two solar canopiesandconnected to each other by a terrain-following drive system. The first solar canopymay be tiltable about a first axis. The second solar canopymay be tiltable about a second axis.

In some embodiments, the drive systemincludes a drivecoupled on a first side (left side in) to an articulating joint, which is coupled to a first output shaft. The driveis further coupled on a second, opposite side (right side in) to a second output shaft. The first output shaftis coupled to the first solar canopy. The second output shaftis coupled to the second solar canopy. Rotation of the drivecauses tilting of the first solar canopyabout the first axis and tilting of the second solar canopyabout the second axis. Because of the articulating joint, the first axis about which the first solar canopytilts and second axis about which the second solar canopytilts need not be the same. In some embodiments, the articulating jointenables the first axis and the second axis to differ by up to about 25 degrees in any direction (whether vertically or horizontally or both). In other embodiments, the articulating jointmay enable the first axis and the second axis to differ by up to about a different maximum number of degrees, e.g., 25 degrees.

In some embodiments, the first solar canopyincludes a first torque tube, first solar panelsand a first support structureattaching the first solar panels to the first torque tube. In some embodiments, the first support structureincludes lateral beams extending in a direction transverse to the first torque tube(e.g., y-direction in).

In some embodiments, the second solar canopyincludes a second torque tube, second solar panelsand a second support structureattaching the second solar panelsto the second torque tube. In some embodiments, the second support structureincludes lateral beams extending in a direction transverse to the second torque tube(e.g., y-direction in).

In some embodiments, the driveincludes a slewing drive that may include a ring gear rotatable by a worm screw. The threads of the worm screw engage teeth of the ring gear. Rotation of the worm screw causes the ring gear to rotate while the threads of the worm screw hold the ring gear in place. On a first side, rotation of the ring gear of the drivecauses rotation of articulating joint, which in turn causes rotation of the first output shaft, which in turn causes the first solar canopyto tilt about its first axis. On the second side, rotation of the ring gear of the drivecauses rotation of the second output shaft, which in turn causes the second solar canopyto tilt about its second axis. In some embodiments, the first axis is colinear with the center of mass of first solar canopy, and the second axis is colinear with the center of mass of the second solar canopy. In some embodiments, the first axis is not colinear with the center of mass of first solar canopy, and the second axis is not colinear with the center of mass of the second solar canopy. Thus, in such embodiments, the motor driving the drivemay require additional torque.

In some embodiments, the articulating jointincludes a universal joint. In some embodiments, the articulating jointmay include a driving yoke, a driven yoke, and a spider (a cross). Rotation of the driving yoke cause the driven yoke to rotate. Because of the design of the universal joint, a torque tube coupled on the side of the driving yoke need not be colinear with a torque tube coupled on the side of the driven yoke. In some embodiments, rotation of the driven yoke causes the first torque tubeto revolve about the first axis, which results in tilting of the first solar canopy. In some embodiments, the articulating jointmay enable angular adjustment between the first axis and the second axis by several degrees, e.g., up to 25 degrees (whether vertically or laterally or both). In some embodiments, a second articulating joint (not shown) may be disposed on the second side of the driveto double the amount of adjustment available between the first axis and the second axis. The second articulating jointmay be desired when the terrain is significantly more uneven than a single articulating jointcan handle.

In some embodiment, the first output shaftincludes a first torque tube interfacedesigned to attach to the first torque tube. Similarly, the second output shaftincludes a second torque tube interfacedesigned to attach to the second torque tube. In some embodiments, the second output shaftis coupled to the drivewithout an intermediate articulating joint. However, as stated above, in some embodiments, an articulating joint may be included therebetween.

The terrain-following tracker systemmay include a drive postand one or more clamping posts (e.g., one or more posts without a drive system). Because of the articulating joint, each post may be equal in height, substantially equal in height, or may have different heights. Instead of having to grade the terrain to be substantially planar, the articulating jointassists the tracker systemto be terrain following. In some embodiments, as will be further illustrated in, the terrain-following tracker systemmay be implemented in conjunction with articulating clamping systems or non-articulating clamping systems.

To add additional terrain-following capability, in some embodiments, the terrain-following tracker systemmay further include a pivotable post bracket systemto support additional adjustment between the first axis about which the first solar canopytilts and the second axis about which the second solar canopytilts. In some embodiments, the pivotable post bracket systemmay only enable additional adjustments in the vertical direction.

In some embodiments, the pivotable post bracket systemincludes a pivoting post bracketattached to the drive postand a drive bracketattached to the drive. The pivotable post bracket systemenables the driveto pivot with regard to the post, which enable the driveto adjust its rotational axis about which it rotates. In some embodiments, the pivotable post bracket systemmay be part of the drive system.

Components may be coupled to one another using any suitable attachment mechanisms, e.g., fasteners such as bolts and screws, welding, or integral formation such as single-piece casting.

illustrates the terrain-following tracker systemincluding the drive systemand the pivotable post bracket systemaccording to some embodiments of the present invention.

As shown, the drive systemincludes the drivecoupled on the first side to the articulating joint, which is coupled to the first output shaft. The driveis further coupled on the second side to the second output shaft. The first output shaftis coupled to the first solar canopy. The second output shaftis coupled to the second solar canopy. As indicated above, rotation of the drivecauses tilting of the first solar canopyabout the first axis and tilting of the second solar canopyabout the second axis. Because of the articulating joint, the first axis about which the first solar canopytilts and second axis about which the second solar canopytilts need not be the same.

As shown, the articulating jointincludes a driving yoke, a driven yoke, and a spiderconnecting the driving yoketo the driven yoke. The driving yokemay rotate about the first axis, and the driven yokemay rotate about the second axis, which may be the same or a different axis. The articulating jointmay contain a driving yoke bracketconfigured to attach to the drive. In some embodiments, the articulating jointmay contain a driven yoke bracket, which attaches to a first output shaft bracketof the first output shaft. In some embodiments, the first output shaftmay contain an offsetting linkattached to a first torque tube interface (see elementof). The offsetting linkdrops the position of the first torque tube interfaceand thus the position of the first torque tubeand its load of solar panels and solar panel structure, bringing the center of mass of the attached first solar canopycloser to the first axis about which it tilts.

Attachment of the first torque tube interfaceto the first torque tubemay be via a respective torque tube openingand an output shaft opening (see elementof) of the first torque tube interface. A fastener such as a pin may be secured in the torque tube openingand the output shaft openingto attach the torque tubeto the first output shaft. Due to the offsetting link, rotation of the driven yokecauses the first torque tubeto revolve about an adjusted axis. The offsetting linkmay have any orientation, shape or configuration, and is not limited to the sloped configuration as illustrated in.

The drivemay attach to a second output shaft bracketof the second output shaft. In a similar manner to the first torque tube interface, second output shaftmay have a second torque tube interface (see elementof), which may attach to the second torque tube. For example, the second output shaftmay also include a second offsetting linkthat repositions the second torque tube interface. The offsetting linkmay have any orientation, shape or configuration, and is not limited to a sloped configuration as illustrated in. The offsetting linkdrops the position of the second torque tube interfaceand thus the position of the second torque tubeand its load of solar panels and solar panel structure, bringing the center of mass of the attached second solar canopycloser to the second axis about which it tilts.

In some embodiments, the pivoting post bracketof the pivotable post bracket systemcontains one or more fastener slots,,,. Although four fastener slots are illustrated, it is understood that the pivotable post bracket systemmay include any number of fastener slots. In some embodiments, the fastener slots,,,may be symmetrically or asymmetrically distributed. In some embodiments, the fastener slots,,,may have a curved or arcuate profile to enable pivotable motion. Fasteners,,, andwithin the fastener slots,,,may affix the pivoting post bracketto the drive post. The pivoting post bracketmay pivot along the fastener slots,,,. Because the drive systemis attached to the pivotable post bracket system, pivoting of the pivoting post bracketcauses the drive systemto pivot.

In some embodiments, fasteners that affix the pivotable post bracketin a fixed position, e.g., to improve fixed alignment of the drive. In some embodiments, fasteners that affix the pivotable post bracketmay enable dynamic repositioning during use, like the articulating joint, e.g., to enable additional terrain following capability.

illustrates an example drive systemin an exploded perspective view according to some embodiments of the present invention. As shown, the drive systemincludes the drivecoupled to the articulating joint, which is coupled to the first output shaft. The driveis further coupled to the second output shaft. The first output shaftis designed to couple to the first solar canopy. The second output shaftis designed to couple to the second solar canopy.

As shown, the drive systemfurther includes a drive motorthat rotates the worm screw, which causes rotation of the ring gear therein. The drive motormay contain any suitable motor, including but not limited to a hydraulic motor, an electric motor, or a pneumatic motor. The drive motormay be connected to the drivevia a drive motor adapter. In some embodiments, the drive motormay contain a slew drive motor.

The driving yoke bracketmay be attached to the driveusing one or more mating fasteners. A mating fastener(e.g., threaded bolt) may be inserted via the ring gear through holes in a first faceplate of the driveinto driving yoke bracket openings(e.g., a threaded opening) of the driving yoke bracket. In some embodiments, the first mating fastenersmay include an elongated nut and the driving yoke bracket openingsmay be replaced with protruding bolts. Alternatively, the first mating fastenersmay include a threaded bolt and the driving yoke bracket openingsmay be through vias, and the mating fastenersmay be secured by nuts. Other alternatives are possible. As shown, the first mating fastenersmay be positioned circumferentially around a periphery of the driving yoke bracket.

The driven yoke bracketmay be attached to the first output shaft bracketvia driven yoke bracket openings, first output shaft bracket openingsand mating fasteners. To secure the driven yoke bracketto the first output shaft bracket, a mating fastener(e.g., threaded bolt) may be inserted through each driven yoke bracket openingand screwed into each first output shaft bracket opening(e.g., a threaded opening). Other mating fasteners such as those described above with regard to the driving yoke bracketare also possible. As shown, the mating fastenersmay be positioned circumferentially around a periphery of the first output shaft bracket.

In a similar manner, mating fastenersmay be mated with second mating fasteners on the driveto attach the second output shaft bracketto the drive. In some embodiments, the mating fastenersmay include threaded bolts which extend through holesin the second output shaft bracketand screw into threaded holes within a second faceplate of the drive. Other fasteners such as those described above with regard to the driving yoke bracketare also possible. As shown, the mating fastenersmay be positioned circumferentially around a periphery of the second output shaft bracket.

Similarly, the drivemay be attached to the second output shaftvia the second output shaft bracket. Mating fasteners (e.g., threaded bolts) may be placed through second output shaft openingsto attach the second output shaft bracketto mating fasteners (e.g., threaded holes) of the drive.

The first torque tube interfacemay have torque tube interface openings, through which a pin may be inserted to secure the first torque tube interfaceto the first torque tube. In some embodiments, the first torque tube interfacemay be inserted into the first torque tubebefore affixing the pins.

Although second output shaft openings, driven yoke bracket openingsand first output shaft bracket openingsare shown as positioned around the periphery in a relatively semicircular pattern, any other patterns of the second output shaft openings, driven yoke bracket openingsand first output shaft bracket openingsare possible. Also, it is understood that the aforementioned openings are merely exemplary, and other attachment mechanisms may be implemented.

is a diagram illustrating a portion of an example drive(e.g., a slewing drive), which includes a ring gearand a worm screw. As shown, rotation of the worm screwby a first amount in the rotational direction α rotates the ring gearby a second amount in the rotational direction γ.